May 25, 2019, 01:42:47 AM
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 RD80 Grease Leakage

normal_post Author Topic:  RD80 Grease Leakage  (Read 634 times)

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November 03, 2018, 07:01:28 PM
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As usual your support is required

We have a Kawasaki robot RD80 , we have changed the grease for all joints since 1 month ago, today we noticed that, there is a big leakage in joint no.1

is there any explanation ????? 

Thanks in advance

Today at 01:42:47 AM
Reply #1



November 03, 2018, 09:24:38 PM
Reply #1


Global Moderator
Yes, there will be an explanation, especially if there was no leakage prior to greasing.
- Can you identify where the leak is coming from by removing it and then periodic checking.
- Did you follow the procedure in the manual, or did you make assumptions (Easy to overlook removing filler and drain plugs and just ram in the new grease and overfill it).
- Did you refit filler and drain plugs and add PTFE to the plugs.

November 04, 2018, 05:26:52 AM
Reply #2



Thank you very much.

Actually, the leak not from port sides ( filler/ drain) , its in joint 1 between the moving part and fixed part ( see attached photo)

One more thing, could you please inform me, what is the right way for grease replacement, while we have in manual the grease volume which should be filled for each joint and at the same time its written in the procedure, after removing the filler and drain ports , start pumping the grease up to see the new grease coming out ,,,,

so, which procedure should I follow ??? filling the required volume in CC or filling up to notice the new grease coming out of drain port ?

November 04, 2018, 08:52:23 AM
Reply #3


Global Moderator
Hmmmm.....the picture is not a good one (in respective of bad news).
- That appears to be old grease (looking at the colour of it).
- I think pressure build up has occurred - did you use hand pump or air pump?
- It appears the seal may have been dislodged.
- You should be able to clean that up and inspect that area for seal exposure - if exposed, then it may require disassemble/removal of base unit to repair (I have never had to replace a JT1 seal, wonder if possible to push back in).

which procedure should I follow  ???  filling the required volume in CC or filling up to notice the new grease coming out of drain port ?

From factory CC amount is original value.
After usage, then new grease and old grease mix, so when new grease comes out, still is mixed with old.
Therefore, you find you may use more than CC amount in manual during service.
So this is judgement really - I always take longer on JT1 for re-grease and monitor pressure for this reason of pressure build up.

Did you use hand pump or air pump?
- Air pumps are very easy to introduce too much pressure and dislodge/damage seals, but make work easier and reduce 'Popeye Arm'

I do not like Kawasaki Maintenance Manuals as they are too literal and do not contain the 'experience' factor.
Gear boxes/reduction units are not a bucket, many areas to create build up of pressure, therefore some additional instructions should be added to manuals to assist a person who has little to no experience....but they do not add.

Even though filler and drain plugs are removed, it is very possible to dislodge seals and also push grease through bearing seals of motor too due to build up of pressure.
Hand pumps do not exert much pressure for this and therefore recommended, but with large CC Volume, you end up with 'Popeye Arm'.....but good seals.
Air pumps make job easier, but more monitoring required during service to make sure pressures aren't too high.

My experience:
- Never just hook pump up and just pump until you use CC volume or you see new grease at drain port, always pump and move, pump and move.
- You should re-grease when robot is warm after use (so old grease is nice and loose).
- As you are pumping against gravity (due to viscosity of old and new grease), you should not just pump away until new grease appears as possible old grease is trapped causing pressure build up.
- You should pump in stages, a little at a time (maybe 200 CC), then move the joint and work it through first, as maybe thick grease lodged and build up of pressure occurs.
- You could also use syringe on drain port to assist and 'suck' grease out if you have one (this helps with reducing any pressure build up - I use one when I do ZX Series JT1).
- Repeat 'pump and move'.
- When new grease is coming out of drain port, still move the joint (as old grease will still be there).
- Service is complete when I see more consistent new grease at drain port.
« Last Edit: November 04, 2018, 09:03:32 AM by kwakisaki »

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